Building construction



June 14,1960 J. A. CARLSON BUILDING CONSTRUCTION 5 Sheets-Sheet 1 Filed liay 2, 1955 PEG, 1

INVENTOR. 5 JOHN A. CARLSON ATTORNEY June 14, 1960 J. A. CARLSON BUILDING CONSTRUCTION 5 Sheets-Sheet 3- Filed May 2, 1955 f on INVENTOR. JOHN A. CARLSON ATTORNEY June 14, 1960 J. A. CARLSON BUILDING cousmumou 5 Sheets-Sheet 4 Filed May 2, 1955 INVENTOR. JOHN A. CARLSON ATTORNEY June 14, 1960 J. A. CARLSON BUILDING CONSTRUCTION 5 Sheets-Sheet 5 Filed Play 2, 1955 United States Patent '0 2,940,294 BUILDING CONSTRUCTION John A. Carlson, 164 Lovell Ave., lVIill Valley, Calif.

Filed May 2, 1955, Ser. No. 505,384

' '4 Claims. (Cl. 72-1) ing houses and other types of buildings durable against -i the most destructive elements such as tornado,.hurricane, earthquake, and Windstorm as well as to provide a shatterproof construction to minimize danger to life and damage to property in the event of enemy attack. Moreover, it is fireproof, vermin proof and permanent in nature providing a building of maximum strength with only a minimum of material. With all of these advantages, applicants invention yet presents a structure competitive in material and erection costs with standard types of frame building construction of equivalent size. Furthermore, being fully insulated, it produces a construction that is cool for hot climates and warm in cold climates and absolutely proof against outside moisture.

This construction provides walls of precast reinforced concrete members and reinforced poured concrete. The precast members are simple to form and are easily and quickly assembled resulting in a sound bonded and practical wall construction. The members are interlocked with specially designed metal rods and fixtures and are then securely bonded together horizontally by embedding their bases in footings and by a poured reinforced concrete girder bonding the upper portions of the members along the top of the wall. 4 Pilasters are obtained by pouring concrete into a preri ,CC.

Fig. 10 is an elevation view of the precast stud member shown in Fig. l in position relative to footing forms and also showing top girder forms in position.

Fig. 11 is an inside elevational view taken on lin 1111 of Fig. 10 and showing the location and-relationship of panel'slabs, studs and interlocking clamps, fixtures and tie rods, top and bottom;

Fig. 12 is a side elevation of an interlocking clamp fixture and rods. Fig. 13 is an end view of Fig. 12.

Fig. 14 is a side elevation of an interlocking tie bar and rods.

Fig. 15 is an end view of Fig. 14.

Fig. 16 is a top end view illustrating forms for providing a take up joint.

Fig. 17 is a side elevation of a wall incorporatingstuds and panel slabs, pilasters, girders and footings.

Fig. 18 is across sectional view taken on line 18-18 of Fig. 16.

Fig. 19 is an enlarged sectional view taken on line 19-49 of Fig. 17 inverted for convenience of illustration and shows particularly a corner pilaster, partition pilaster, and insulation material fastened to the-precast members.

Fig. 20 is a perspective view illustrating studs and panel slabs in position after footings and top girder have I been poured, comprising-a section of a 'wall.

arranged mold formed essentially of the precast members themselves. Such pilasters may be formed at intervals from corner to corner or to points adjacent the joinder of a partition wall to the outside wall.

The provision of such precast members, fixtures and rods referred to above, together with their assembly into a wall construction, as well as the resultant wall, constitutes the principal object of this invention.

Additional objects and advantages of this invention will become more apparent as the following description proceeds when taken in conjunction with the accompanying drawings, in which:

Fig. 1 is an elevational view of a precast stud member.

Fig. 2 is an enlarged top end view of the member illustrated in Fig. 1. I

Fig. 3 is an enlarged cross section taken on line 33 of Fig. 1.

Fig. 4 is an elevational view illustrating the surface side of a panel slab.

Fig. 5 is a bottom end view of the panel slab in Fig. 4.

Fig. 6 is an elevational view of the inner surface of the panel slab in Fig. 4.

Fig. 7 is a vertical section taken on line 77 of Fig. 6.

Fig. 8 is a top end view of the panel slab illustrated in Figs. 4 and 6;

Fig. 9 is a cross sectional view on line 9-9 of Fig. 6.

Fig. 21 is a perspective view similar to that of Fig. 20 illustrating the arrangement of members andpoured concrete for multiple story construction.

Fig. 22 is an elevational view illustrating the surface side of a panel slab into which plumbing pipes and fixtures such as for example vent and sewer pipes; have been cast.

Fig. 23 is a side end view of Fig. 22.

Fig. 24 is an elevational view illustrating the surface side of a panel slab into which electrical service receptacles have been cast.

Fig. 25 is a side end view of Fig. 24. a

Fig. 26 is a cross section illustrating studs, panel slabs and pilasters specially adapted for warehouse construction purposes.

Fig. 27 is a cross section on line 27-27 of Fig. 26 illustrating top girder forms to achieve the construction shown in Fig. 28.

Fig. 28 is a side elevation of the wall shown in including footings and top girder.

Referring now more particularly to the drawings, in Figs. 1, 2, and 3 there is illustrated a stud member 30. The stud 30 in the embodiment illustrated comprises a pair of laterally spaced parallel columns 31 and 32 which are integrally joined at least at the bottom by a reinforced cross member 33. To maintain the parallel spaced relation of the columns 31 and 32, they are provided with several cross rods such as 34, 35, 36 and 37 extending therebetween and the ends of which are firmly embedded in' the material forming the columns 31 and 32. The upper ends of the columns 31 and 32 are each provided With a shoulder or ledge 38 and 39. Above the ledges 38 and 39, the internal walls 40 and 41 of the columns taper upwardly so that the central opening reaches maximum width at the top. The upper extremities 42 and 43 of the columns may be at right angles to the outside surfaces 44 and 45 but for a better bond with the poured concrete top girder as described in greater detailhereinafter, may preferably taper slightly downward to the outside surfaces 44 and 45 of the columns 31 and 32. Each lateral longitudinal edge of the columns 31 and 32 is provided with guide like runners 46 and 47 of frustrum cross section. The entire stud member, thoroughly reinforced with steel, is formed of concrete as a unitary Fig. 26

. member pouredin a mold. to form the, various parts as.

described'above.

. In Figs. 4, 5, 6 and 7 there is shown a concrete panel 'SlhbSQ-the outer surface; 51 of which may be smooth o1,- slightlyroughened :asg'desfired. .The other or inside surface of thepanel slab. 50 is preferably formed with aipluralitx or stiffening r ibs .5256 extending along the sides of the panel as well as across the panel betFYPQ fic-laterlal ribs. 52; 'The upper end. of the'panel slab 50 is provided with-a; shou'lder'or ledge 57; -Above thqledgej 57-, as was; the case with the stud 3%, arr in- "ternal surface 58 is provided tapering upwardly to the top in a direction toward the; outer surface;'51; Here agai nthe'upper extremity 5910f the panel slab50, like the upper extremities of the stud 3t), taper slightly downwardly to the outer surface Sglf (see Fig. .7). The, lower 6,0 of the panel slab .0 is 'of' reduced width, the purpose of which will appear later; The lateral edges 61; and 6 2 ofthe reduced portion .60 are bevelled out-- with expensive mold casts and-'are amply reinforced with t 5."'

. Ii rning new to Figs. Ill-15 fora discussion of the manner in which a wall comprising a series of concrete studs fill and; panel-slabs 50 is assembled, 70 indicates removable-forms into which concrete is poured to? form the, necessaryfootings. The footing forms 70 comprise parallel retaining members 71 and 72 which may consist apart by 'means of; a separator tube orpipe 73. The relative positions of the retaining members 71 and 72 tially filled with a mastic cement and then pressed into engagement with the guide runners 46 and 47 on the several; inches shorter. than the studs i. TheSepanel 'glahsare; precast in several practical widths consistent of planking, steel channels or the like; uniformly spaced 7 i are securely maintained by a rod member 74 extending r through the tube 73 and bores in the retaining members,

after nuts 75 an d 76; havev beemtightenedr To facilitate.

theftightening of the members 71, 72,.if made ofwood, suitable inner and outer washers are employed between the tube,73 and the planking 71 and 72 andbejtween n pig gt na the nuts 75 and 1s; Paralleling" and spaced from one of the retaining members, 71 for ex- .tie bo lts 79 .which extend; through bores previously-drilled in; the angle. ironsv at selected spacing to coincide with the'openings providedby the reduced bottom ends 60 of thepanel slabs50.

: fljheremaining members will be best described in the discussion: of. the procedureoferecting a section of a wall incorporating the heretofore detailed studs 30, panel slabs and; footing forms 70, to follow. It should be notedthat afterthejformsmhave been placed in the out.- lineof the buildingto be constructed, and the angle iron is weldedin its proper place in the footing form,

there, is no further'ne d' ofa rule .orother measuring device to complete the outside walls. 7 t Ind 30 is placed erect between th'etwo angle irons and 781 intermediate apair of cross tie bolts 79 which; atter he stud has been plumbedtrue, are tightened to; securely hold the stud between the angle irons.

To. this said are applied two pane-lslabs 50 by placing therri with their face surfaces 51"outward and their reduced base portions resting opposite each other and "spaced apart in-the angle irons-77 and-78.- The vertical stud. Another stud 39 is then placed between the angle irons 77 and 78 intermediate the next pair of cross tie bolts 79, and pressed against the mastic filled grooves 65 and 65 of the other lateral edges of the panel slabs 5%": already erected. This stud is again plumbed after which the tie bolts 79 are tightened to holdlt in place.

At this time a clamp fixture 8 (see Figs. '12 and 13) having an upper body portion 81 bored at 82, and having a lower body portion SS fGl'HllHg Wlth the upper body portion 81 a hook 84. to engage a cross rod such as 34 of the studs 30 in a directiontr'ansverse to the axis of the bore 83, is engaged with tie rod 34 between the dual columns of the stud 30. A tie rod in length equal to the width of a panel slab 59 plus the width of a stud 39, threaded at bothends; andanchored' to the next previous stud,v is inserted through bore 82 of fixture as. A sleeve nut 86. is turnedonto the end of the rod 35, thereby drawing the two studs 30 with the panel slabs 5b. therebetween tightly together. The other end of the sleeve nut 36 is open and free to receive the next tie rod 85: to secure the next'set of two panel slabs and a stud thereto. i

Nearthe baseof the stud EQ'anothe-r tie rod 85, previously secured to the next preceding stud, extends between and beyond thecolunms of stud 39. A bar 5 preferably in the form of a channel member and can trally'borcd at 91 isplaced crosswise of the stud 39, over thethreaded end of this tie'rod 85, and another sleeve nut 86 is turned ont'o'it clamping securely at the bottom the pair of panel slabs 50, between the studs 3%}. it should be noted that the'clamping' bar 90 is located withinthe openings; providedby' the reduced bottom ends 69 of the panel slabs St). The otherz d of hi Slew;

nut 85 is open and free to accept the next tie rod 85, which withthe following clamping bar W secures the next set of: two panel slabs 50 and a stud- 30 thereto. This procedure, top and bottom, proceeds in repeated sequence assucces'sive sets of slabs and'studs are erected until substantially an entire wall between any two pilas- 'ters is erected.

t The panel slabs are made in several convenient and practical widths.

Where variations in wall measurements: difier frompanel width multiples, a take up joint may bet-necessary; Such a take'up joint is illustrated in Fig. 16 and'simply comprises pairs ofna'rrow-steel plates 101 and lfl2; suitably bored. Between the plates 101 and102 and in register with the bores' are inserted ferrules 103 throughwhioh. bolts-104 extend. The bores of the inner plates 102 are tapped to receive the bolts 1M:

so that the plates maybe drawn together overlappingly between the last pair of studs 39 in a wall, as indicated in the illustration. will; be brought out lateryall of the panel slabs 50'and studs 39 are insulated. This insulation is also carried out. in the take up joint by providing insulation material of appropriate width and coveredwith asphaltum compound, held in place temporarily against the inner form plate 102,: and extending from the footings. to the top of the joint. 7

' Fine. concrete, equivalent to, the panel slab and stud material is then poured between the steel plate forms. After. concrete has; been set and, seasoned, the forms 101 and 102 are easily removed by withdrawing bolts 1&4. Afitera reasonable; length 'ofwallg'section, or a wall section between two pilasters has been erected as discussed above, a thin gauge-steel; plate 951 is dropped in place on the1ledges.-'38 and 39: of.- studs 30', and ledg'es57 of the panel slabs 50. Plate serves several purposes. It acts as a straight edge to absolutely align the studs 30 'into conformitywith the angleirons-77, 78 at the base.

This steel plate 95 also provides a bottom closure for thepouring of a top-girder for the wall tobe' described below. Steel plates 95 are inserted around the entire top portion of the wall.

The top wall girder to be made and referred to above is formed by utilizing a form structure similar to that described in connection with the forms 70 for forming the base footings.

Parallel retaining form members 96 and 97 are drawn together against the face surfaces of the upper ends of the studs 30 and panel slabs 50, and against a spacing ferrule 98 by means of a tie rod 99 extending through holes bored in the form members 96 and 97 and the ferrule 98, and suitable washers and nuts in the same manner as described with reference to the setting up of the footing forms 70. The spacing ferrules 98 rest on the top edges 59 of the panel slabs 51) which as noted before, are shorter by several inches in length than the studs 30, the specific purpose for which will be brought out further along. Steel reinforcing, not shown, is incorporated into the top girder to be poured according to accepted standards. Such reinforcing steel may conveniently rest on the ferrules 98.

After the top and bottom forms are thus in place and a final check is made to insure that the members are plumb, concrete is then poured into the footings. All of the tie rods 35 and clamp bars 90 at the bottom are submerged in the concrete footings when poured, adding additional reinforcing material thereto and further assuring the lock-bonding of precast members 30 and 50 in the concrete footings.

After the footing concrete has set, the top wall girder is completed by pouring concrete between the forms 96 and 97 and above the closure plate 95 to the top of the forms. The height of the forms 96 and 97 is determined by the height of girder desired.

In certain instances, the construction may not require a top girder in excess of that which can be provided by the upper portions of the studs 30 and panel slabs 50 above the steel plate 95. In such cases, instead of the forms 9698, panel slabs in all other respects the same as panel slabs 50 but equal in height to studs 30, are employed.

Figs. 17 and 18 illustrate a finished section of wall, emphasizing the simplicity and ease whereby members already in place provide forms for filling with concrete, resulting in pilasters and girders, with only a minimum amount of form work required. The results provide well recognized pilaster and girder construction for the build ing. These figures also clearly illustrate in a finished section of a wall, the interlocking and bonding together of the wall girder 105, corner pilaster 110, partition pilaster 115, footings 120, studs 30 and panel slabs 50. It will also be noted with respect to the footings 120, that the purpose for malcing the base portions 60 of panel slabs 50 of reduced width, is to enable concrete poured into the footing forms 70 to flush and fill between the bases of the dual columns of the studs 30 and between the bases 60 of the panels 59 to the height of the footing forms 70. This is additionally illustrated in Fig, 20. The bevelled sides 62 of the bases 60 provide a further dovetail lock in the concrete footings.

Fig. 19 illustrates in greater detail the points covered above. In addition it shows the simplicity of forming the pilasters by inserting thin gauge steel plates 116 in the joints between the studs 30 and the panel slabs 50 which together-with the members already in place automatically provide a form for the concrete to be poured, resulting in the pilasters referred to. The inner joints of the studs 30 and of the panel slabs 50 are all cast with sufficient space to accommodate these steel plates 116 wherever pilasters are required. For corner pilasters 110 it is only necessary to complete the corner by adding an exterior sheet metal angle form 111 and an interior angle strap iron 122 which are secured in place for pouring by spacing ferrules 113 through which bolts 114 extend into tapped bores in the sti'ap iron angle 112.

Fig. 19 also clearly illustrates insulation material 125 as it is permanently incorporated in the finished wall. This insulation material is prefabricated in appropriate widths and lengths to completely cover down to the top level of the footings the inside surfaces of the dual columns of the studs 30 and the inside surfaces of the panel slabs 50. It is secured to these inner surfaces of the various members after they have been cast, cured and dried preferably in the following manner. The entire inner surfaces of the studs and slabs are coated with a moisture proof asphaltum compound, and while wet, the insulation material 125, meeting accepted standards for the particular insulating value required, is pressed and bonded thereby to the various inner surfaces. This procedure provides precast and prefabricated insulated memhers, to be installed in place as a finished unit. The panel slabs 5i) automatically include insulating values in the form of the air spaces 170 between the panel surface and the insulating material 125, which amounts to approximately two thirds of the entire wall area, inside and outside. These air spaces 170 are in addition to the larger air spaces provided inthe center of the wall. Such a. triple airspace wall assures outstanding insulating values and which, due to the asphaltum material applied to the inner surfaces of all members, also insures a positively moisture proof wall.

Figs. 20 and 21 illustrate particularly the finished girder and the relationship of the upper portion of the studs 30 and the panel slabs 50 embedded in the concrete of the girder 105. This view specially illustrates the importance of the bevelled tops 42 and 43 of the studs 30 and the bevelled tops 59 of panel slabs 50. These bevels provide interlocking dovetails in the concrete girder 105. It also shows with particular clarity the influence of the steel plate closure 95 in the finished wall. It further illustrates the finished footings and shows how thoroughly the bases of the studs 30 and panel slabs 50 have been embedded in the footings, including concrete reaching footing height level between the members.

Fig. 21 illustrates the same general principle of footings 120 and top girders in connection with a multiple story structure, and the manner in which the stud'and panel slab members of the upper story are bonded to the stud and panel slab members of the story directly below. The bonded girder between the floors is achieved by forms similar to forms 96--99 positioned after the floor joists 131 have been put into place at desired spacings in the openings provided by the reduced portions 60 of the upper panel slabs 50.

This multiple story construction is also very useful for the purpose of increasing or adding an additional number of stories to the top of a building of conventional construction already constructed. In this manner no hazardous forms or scafiolds which hang out over the outside walls on the exterior would be required. Likewise the hazardous work of afterward removing such forms and scaffolds is also eliminated, and consequently the incident material and labor costs which would otherwise have been involved will be reflected in a lower overall cost for the job.

Figs. 22, 23, 24 and 25 illustrate prefabricated panel slabs and into which sewer and vent pipes 141 and electrical service receptacles 151 are included as part of the panel slabs as cast.

All of the precast members, such as studs 30 and panel slabs 50 are provided with internal reinforcing of steel, such as rods, wire or mesh as appropriate. This of course is accomplished in the casting of these members. Likewise, all of the poured concrete such as the footings, pilasters and girders are provided with steel reinforcing material according to accepted standards.

After the balance of a building has been completed including floor, ceilings and roof, the interior surfaces of the walls may be finished with plaster and the exterior 'lustrated will be suggested to those skilled in the art.

with a trowelled or pebble dashed cement finish, or any other interior and exterior finishesthat may be-desired.

the same manner as pilasters 1 10 and 115 except that the steel plates 1 16 for completing these pilasters' are providedwithrodslfil to help hold them in place. Members 117 in the nature otwood templates are used as space I maintainers during the time when the fixtures 8i), clamp 7 bars 90and tierods 85, are tightened into place with sleeve the tie rods 85 and clamp-bars90 at the bottom are submerged in the'concrete footings when poured adding addltional reinforcing and further assuring the lock-bonding of members 30 and 50 in the concrete footings,

The top girder 162 for this type of construction is in most respects achieved in the same manneras are girders 105. However, since only one side is provided with panel slabs 50,- after the plate 95 has been placed on the ledges 38 and 39 of the studs 30, and the forms 9699 have been secured in place, theremaining space between the plate 95, and the form retainer 96 is covered with a sheet metal angle 163'. To support the sheet metal angle 163, the retainerform 96 is of slightly lesser depth than retainer 97 and a cleat 164 is secured to its underside and projects inwardly between the stud members 30 as illustrated. Concrete is then poured into the form.

Fig. 28 illustrates the outer appearance ofja wall sec-i 'tion for warehouse purposes showing anelevated con in the novel. combinationand cooperation ofthe various members together with'the method of their assembly and the method of bonding them in concrete poured in part at least in forms furnished by the members'themselves,

and'that certain modifications in the arrangements ils'uch modifications as come Within the spirit of this in vention areintended to be within its scope as best defined in theappendedcla-ims. a i

' I claim: i

' 1. Wallconstruction for buildings comprising in combination, precast studs each having spaced apart dual columns,.cross tie means extending between the spaced apart dual columns of the studs,.precast panel slabs spaced apart and, P essed betwieenc pairs of said studs, tie rod means extending transverse to' said cross tie means and secured thereto and mechanically clamping said studs and panel slabs rigidly in place, the upper ends of said studs and panel slabs being provided with shoulders in alignment, the inner walls of'said studs and panel slabs above said' shoulders inclined upwardly toward the outer faces thereof: pilasters positioned at corner wall'intersections; said pilasters including a precast stud from each of the intersecting wall sections, abutted at the inside corner of the intersection, a corner column of poured concrete securedto said abutted pair of studs and formedto provide the outside corner of said intersectiomand another column of poured concrete filling the space between said abutted pair of studs and said corner column secured thereto:

All a thus providing a continuous central airspace within the wall, between said pilasters, 'concretelfootings, said studs and panel slabs embedded within saidifolotings and one ofsaid cross ties and tie rod means also embedded firmly therein, a supporting platesnugly insertedlbetween said dual columns on said shoulders, and a. poured concrete girder resting in .partat' least on said plate and the inclined' inner Walls of said studs and panel slabs above said aligned shoulders thus providin'ga monolithic bond with said pilasters and footings, in which monolithic bond said precast studs and panel slabs are secured.

2. Wall construction for buildings as claimed in claim 1, in which said plate is steel and provides a straight edge aligning the. precast studs and panel. slabs, j 1

3. Wall construction as .claimed in claim 1, in which the bottom portions of thepanel slabs embedded within the footings, are of reduced .width, the edges of which are beveled, said beveled edgesfurther lock-bonding the panel slabs in the footings. i i

4. Means for pouring concrete for footings andv for setting up wall construction to be embedded in said footings, comprising retaining members for said poured concrete, tie rod means for maintaining said retaining members in spaced apart relationship, an angle iron fixedly secured to said tie rod means in preselected spaced rela' tionship to the adjacent retaining member for said concrete, another angle iron movable with respect to said fixedly secured angle iron resting on said tie rod means, and additional tie rod means, shorter than said first mentioned tie rod means extending between and adjustably connecting said angle irons relatively at preselected intervals whereby upright studding placed between said angle irons at selected intervals may be clamped in'place therebetween by the tightening of said additional. tie rod means and maintained in alignment predetermined by said fixedly secured angle iron.

I References Cited in the file of this patent UNITED STATES'PATENTS 1,072,230 Howard Septi 2,,(19113 1,132,995 Anderson Mar. 23, 1915 1,343,926 Madsen -Junei 22, 1920 1 ,500,445 Dvorak July 8, 1924 1,519,305 Hahn Dec. 16, 1924 1,698,557 vQBrien Ian. 8, 1929 1,730,533 Rose Oct: 8, 1929 1,836,408 Sutton Dec. 15, 1931 1,897,327 Olson Feb. 14, 1933 1,963,410 Kartowicz June 19, 1934 1,985,328 Rutten Dec; 25', 1934 2,058,285 Amesuca Oct. 20, 1936 2,083,781 Groves June 15, 1937 2,114,048 'Davis ,Apr.'12, 1938 2,234,797 Burner Mar. 11, 1941 2,295,216 Joy Sept. 8, 1942 2,372,038 Westveer Mar. 20, 1945 2,373,409 Myer Apr. 10, 1945 2,741,908 Swans0n. Apr. 17-, 1956 FOREIGN PATENTS 60,012 France Mar. 24,1954 126,155 iAustralia of 1947 157,210 Australia June 24, 1954 166,313 Austria of 1950 341,501 Germany of 1921 France of 1948 

